Method of making a carbon monofluoride impregnated current collector including a 3D framework

ABSTRACT

One example includes a battery case sealed to retain electrolyte, an electrode disposed in the battery case, the electrode comprising a current collector formed of a framework defining open areas disposed along three axes (“framework”), the framework electrically conductive, with active material disposed in the open areas; a conductor electrically coupled to the electrode and sealingly extending through the battery case to a terminal disposed on an exterior of the battery case, a further electrode disposed in the battery case, a separator disposed between the electrode and the further electrode and a further terminal disposed on the exterior of the battery case and in electrical communication with the further electrode, with the terminal and the further terminal electrically isolated from one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 13/205,757,filed Aug. 9, 2011, now issued as U.S. Pat. No. 9,083,048, which claimsthe benefit of U.S. Provisional Application No. 61/373,086, filed onAug. 12, 2010, under 35 U.S.C. § 119(e), each of which is incorporatedherein by reference in its entirety.

TECHNICAL FIELD

This document relates generally to energy storage and particularly to acarbon monofluoride (CF_(x)) impregnated foam current collector.

BACKGROUND

Some electrochemically active battery materials offer superior energydensity, but are difficult to implement in a battery using traditionalbattery manufacturing structures and materials. Specifically, somebattery manufacturing structures and methods can render certain batterychemistries less effective. Structures and methods that enable using newbattery chemistries would be beneficial.

SUMMARY

A first example includes a battery case sealed to retain electrolyte, anelectrode disposed in the battery case, the electrode including acurrent collector formed of a framework defining open areas disposedalong three axes (“framework”), the framework electrically conductive,with active material disposed in the open areas, a conductorelectrically coupled to the electrode and sealingly extending throughthe battery case to a terminal disposed on an exterior of the batterycase, a further electrode disposed in the battery case, a separatordisposed between the electrode and the further electrode, and a furtherterminal disposed on the exterior of the battery case and in electricalcommunication with the further electrode, with the terminal and thefurther terminal electrically isolated from one another.

Example 2 includes the subject matter of example 1, wherein theframework is formed of a compressed metallic foam defining open areas.

Example 3 includes the subject matter of examples 2, wherein themetallic foam is formed of at least one of the group including aluminum,titanium and stainless steel.

Example 4 includes the subject matter of any of examples 1-3, whereinthe active material includes, but it not limited to, carbon monofluoride, with a formula CFx.

Example 5 includes the subject matter of example 4, wherein theelectrode has a porosity of from around 30-55% porous.

Example 6 includes the subject matter of any of examples 1-5, whereinthe electrode is disposed in a stack of electrodes.

Example 7 includes the subject matter of example 6, wherein the stack ofelectrodes includes a further electrode including a current collectorformed of a compressed framework that is electrically conductive.

Example 8 includes the subject matter of example 7, wherein the stack isformed by a process including stacking an uncompressed electrode and afurther uncompressed electrode into an uncompressed stack, and stackingthe uncompressed stack.

Example 9 includes the subject matter of any of examples 1-8, whereinthe stack is a stack of compressed electrodes, each adapted to stackinto the stack.

Example 10 includes a hermetically sealed device housing, a batterydisposed in the hermetically sealed device housing, the batteryincluding a battery case sealed to retain electrolyte, an electrodedisposed in the battery case, the electrode including a currentcollector formed of a compressed framework defining open areas disposedalong three axes (“framework”), with active material disposed in theopen areas, a conductor electrically coupled to the electrode andsealingly extending through the battery case to a terminal disposed onan exterior of the battery case, a further electrode disposed in thebattery case, a separator disposed between the electrode and the furtherelectrode, and a further terminal disposed on the exterior of thebattery case and in electrical communication with the further electrode,with the terminal and the further terminal electrically isolated fromone another, and an electronic cardiac rhythm management circuit coupledto the battery and adapted to discharge the battery to provide atherapeutic pulse.

Example 11 system of claim 10, wherein the device housing has a formfactor, and the battery case is shaped to at least partially conform tothe form factor.

Example 12 system of claim 11, wherein the battery case has a caseshape, and the electrode has an electrode form factor shaped to at leastpartially mate the case shape.

Example 13 includes disposing active material into a current collectorincluding a framework defining open areas disposed along three axes(“framework”), curing the active material to the current collector,compressing the framework into a shaped electrode, stacking the shapedelectrode into a battery stack with other electrodes, disposing thebattery stack in a battery case, connecting the electrodes of thebattery stack to terminals for coupling to electronics, filling thebattery case with electrolyte, and sealing the battery case.

Example 14 includes the subject matter of example 13, further includingforming the framework out of a metallic foam.

Example 15 includes the subject matter of any of examples 13-14, furtherincluding forming the active material by mixing active materialincluding, but not limited to, carbon monoflouride, into a slurry withbinder and conductive additive.

Example 16 includes the subject matter of example 15, wherein disposingactive material includes injecting the active material into theframework.

Example 17 includes the subject matter of example 16, wherein curing theactive material includes baking the active material in an oven.

Example 18 includes the subject matter of example 17, whereincompressing the framework includes compressing to a porosity of fromaround 30% to 40%.

Example 19 includes the subject matter of example 18, further includingcutting an excised electrode from the shaped electrode.

Example 20 includes the subject matter of example 19, further includingstacking the other electrodes into the stack such that the stack has apredetermined energy density.

This Summary is an overview of some of the teachings of the presentapplication and not intended to be an exclusive or exhaustive treatmentof the present subject matter. Further details about the present subjectmatter are found in the detailed description and appended claims. Otheraspects of the invention will be apparent to persons skilled in the artupon reading and understanding the following detailed description andviewing the drawings that form a part thereof. The scope of the presentinvention is defined by the appended claims and their legal equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate generally, by way of example, various examplesdiscussed in the present document. The drawings are for illustrativepurposes only and may not be to scale.

FIG. 1 is a schematic of a medical system including a battery thatincludes a fluorinated carbon framework defining open areas disposedalong three axes, according to some examples.

FIG. 2 is an implanted medical system including a battery that includesa fluorinated carbon framework defining open areas disposed along threeaxes, according to some examples.

FIG. 3A is a perspective view of a fluorinated carbon framework definingopen areas disposed along three axes, according to various examples.

FIG. 3B is a close-up view of a fluorinated carbon framework definingopen areas disposed along three axes such as the close-up view 3Bdepicted in FIG. 3A.

FIG. 4A is a plan view of a fluorinated carbon framework defining openareas disposed along three axes, according to various examples.

FIG. 4B is a cross section taken along line 4B-4B in FIG. 4A.

FIG. 5A is a perspective view of an electrode, according to someexamples.

FIG. 5B is a cross section taken along line 5B-5B.

FIG. 6A is a perspective view of an electrode, according to someexamples.

FIG. 6B is a cross section taken along line 6B-6B.

FIG. 7A is a perspective view of an electrode, according to someexamples.

FIG. 7B is a cross section taken along line 7B-7B.

FIG. 8A is a plan view of a battery, according to various examples.

FIG. 8B is a cross section taken along the line 8B-8B in FIG. 8A.

FIG. 9 is a method of making a battery including a fluorinated carbonframework defining open areas disposed along three axes, according tosome examples.

FIG. 10 is a method of making a battery including a fluorinated carbonframework defining open areas disposed along three axes, according tosome examples.

FIG. 11 is a method of making a battery including a fluorinated carbonframework defining open areas disposed along three axes, according tosome examples.

DETAILED DESCRIPTION

The following detailed description of the present invention refers tosubject matter in the accompanying drawings which show, by way ofillustration, specific aspects and examples in which the present subjectmatter may be practiced. These examples are described in sufficientdetail to enable those skilled in the art to practice the presentsubject matter. References to “an”, “one”, or “various” examples in thisdisclosure are not necessarily to the same example, and such referencescontemplate more than one example. The following detailed descriptionis, therefore, not to be taken in a limiting sense, and the scope isdefined only by the appended claims, along with the full scope of legalequivalents to which such claims are entitled.

Examples discussed here relate to electrochemical batteries includinglithium. In some examples, the anode (or negative electrode) is formedfrom lithium. In certain examples, a cathode (or positive electrode) isconstructed of a mass formed at least partially of carbon. In someinstances, the mass is porous. The mass is formed onto a currentcollector formed of a framework defining open areas disposed along threeaxes, (as used herein, a “3D framework”). For example, an opening isbounded by edges defining the opening along three axes. The edgesdefining the opening define planes enclose the opening on all sides.Some instances relate to a lithium primary battery.

Li/MnO₂ battery systems, such as those operating at or around 3.0V, canbe improved upon. The present subject matter addresses at least oneproblem with these battery systems: the energy density of Li/MnO₂batteries is difficult to increase, due to the capacity of MnO₂ and itsmaximum loading level. Loading level refers to the amount of activematerial per unit area (i.e., g/cm²). CF_(x) batteries provide anopportunity to improve energy density, but existing CF_(x) designs havedrawbacks.

CF_(x) chemistry has an energy density of around 1.5 times that of MnO₂.However, CF_(x) electrodes are difficult to process in the form of acoated or pelletized electrode. For example, at the end of the dischargeof a Li/CF_(x) battery, the cathode can expand by as much as two tothree times, limiting full utilization of the CF_(x) energy density.

To address inefficiencies that result from the poor electronicconductivity of CF_(x), some designs use a high percentage of conductiveadditives, such as acetylene black carbon, to achieve an acceptablelevel of electronic conductivity. Some of these designs have a porous(e.g., >50% porous) electrode with poor volumetric capacity as a resultof the poor tap density of acetylene black carbon. While increasing thesize of current collectors addresses certain aspects of the problem, asize increase is not sufficient, as portions of the current collectorstill fail to adequately conduct with parts of the electrochemicallyactive area of the CF_(x). Further, size increases are undesirable inimplantable devices, as increased size leads to patient discomfort.

Despite these issues, the Li/CF_(x) chemistry is desirable. CF_(x)batteries feature high volumetric capacity. CF_(x) batteries havedesirable long term stability. Some have less than one percent selfdischarge per year, for example. CF_(x) batteries have desirable voltagecharacteristics. Some have an open circuit voltage of around 3.2 volts,for example. Some have a closed circuit voltage of around 2.5 to 2.7volts, for example. CF_(x) batteries additionally have predictable lowto medium rate performance.

Because CF_(x) offers these benefits, various examples provide a currentcollector to combine CF_(x) with a 3D framework. The 3D framework iselectrically conductive. The 3D framework together with active materialcomprises a cathode in various examples. Various examples provide a 3Dframework for the CF_(x) cathode that addresses the above inefficienciesto provide a CF_(x) battery that discharges well and has an improvedenergy density. In certain examples, the 3D framework is porous, but thepresent subject matter is not so limited. Certain examples include foam.Various examples are metallic. Additional 3D frameworks include fabrics,thatches, braids, scaffolding, skeleton, fins, tendrils and the like.The 3D framework examples disclosed here include features that can beused in combination, that is, aspects from one 3D framework arecombinable aspects from another 3D framework, in various examples.

FIG. 1 is a schematic of a medical system including a battery thatincludes a 3D framework, according to certain examples. The system 100represents any number of systems to provide therapeutic stimulus, suchas to a heart. Examples of medical systems include, but are not limitedto, implantable pacemakers, implantable defibrillators, implantablenerve stimulation devices and devices that provide stimulation fromoutside the body, including, but not limited to, externaldefibrillators.

In various examples, electronics 104 are to monitor the patient, such asby monitoring a sensor 105, and to monitor and control activity withinthe system 100. In some examples, the electronics 104 are to monitor apatient, diagnose a condition to be treated such as an arrhythmia, andcontrol delivery of a stimulation pulse of energy to the patient. Insome instances, electronics 104 are powered wirelessly using aninductor. In additional configurations, the electronics 104 are poweredby a battery 106. In some examples, electronics 104 are to direct smalltherapeutic bursts of energy from the battery 106 to a patient.

For therapies that use energy discharge rates exceeding what battery 106is able to provide, such as defibrillation, a capacitor 108 is used.Energy from the battery 106 is controlled by the electronics 104 tocharge the capacitor 108. The capacitor 108 is controlled with theelectronics 104 to discharge to a patient to treat the patient. Incertain examples, the capacitor 108 completely discharges to a patient,and in additional examples is switched on to provide therapeutic energyand switched off to truncate therapy delivery.

Some instances of a system 100 include an optional lead system 101. Incertain instances, after implantation, the lead system 101 or a portionof the lead system 101 is in electrical communication with tissue to bestimulated. For example, some configurations of lead system 101 contacttissue with a stimulation electrode 102. The lead system 101 couples toother portions of the system 100 via a connection in a header 103.Examples of the system 101 use different numbers of stimulationelectrodes and/or sensors in accordance with the needs of the therapy tobe performed.

Additional examples function without a lead 101 and are leadless.Leadless examples are positioned in contact with the tissue to bestimulated, or are positioned proximal to a tissue to be stimulated toshock the tissue through intermediary tissue. In certain examples,leadless systems are easier to implant and are less expensive as they donot use additional lead components. The housing 110 is used as anelectrode in leadless configurations, in certain examples.

In certain examples, the electronics 104 include an electronic cardiacrhythm management circuit coupled to the battery 106 and the capacitor108 to discharge the capacitor 108 to provide a therapeuticdefibrillation pulse. In some instances, the system 100 includes ananode and a second electrode such as a cathode sized to deliver adefibrillation pulse of at least approximately 50 joules. This energylevel is predetermined to achieve a delivered energy level mandated by agoverning body or standard associated with a geographic region, such asa European country. In an additional example, the anode and secondelectrode are sized to deliver a defibrillation pulse of at leastapproximately 60 joules. This energy level is predetermined to achievean energy level mandated by a governing body of another region, such asthe United States. In some instances, electronics 104 are to controldischarge of a defibrillation pulse so that the medical system 100delivers only the energy mandated by the region in which the system 100is used.

In certain examples, the battery 106 includes a battery case 114 sealedto retain electrolyte. In certain examples, the battery case 114 iswelded. In some instances, the battery case 114 is hermetically sealed.In additional examples, the battery case 114 is sealed to retainelectrolyte, but is sealed with a seal to allow flow of other matter,such as gaseous diatomic hydrogen or a helium molecule. Some of theseexamples use an epoxy seal. Several materials can be used to formbattery case 114, including, but not limited to, aluminum, titanium,stainless steel, nickel, a polymeric material, or combinations of thesematerials. The battery case 114 is sealed to retain electrolyte. Thebattery case 114 includes a seal, such as a resin based seal includingbut not limited to epoxy, in some examples. Certain examples include arubber seal to seal multiple case portions to one another, or to sealsubcomponents such as a feedthrough to one or more case portions. Incertain examples, the battery case 114 is welded together fromsubcomponents. Some instances include a case that includes one or morebackfill ports, but the present subject matter is not so limited.

In certain examples, the capacitor 108 includes a capacitor case 112sealed to retain electrolyte. In some examples, the capacitor case 112is welded. In some instances, the capacitor case 112 is hermeticallysealed. In additional examples, the capacitor case 112 is sealed toretain electrolyte, but is sealed with a seal to allow flow of othermatter, such as gaseous diatomic hydrogen or a helium molecule. Some ofthese examples use an epoxy seal. Several materials can be used to formcapacitor case 112, including, but not limited to, aluminum, titanium,stainless steel, nickel, a polymeric material, or combinations of thesematerials. The capacitor case 112 is sealed to retain electrolyte.Various electrolytes can be used including, but not limited to,Suzuki-Techno Corporation electrolyte model 1184. The capacitor case 112includes a seal, such as a resin based seal including but not limited toepoxy, in certain examples. Some instances include a rubber seal to sealmultiple case portions to one another, or to seal subcomponents such asa feedthrough to one or more case portion. In some instances, thecapacitor case 112 is welded together from subcomponents. Certainexamples include a case that includes one or more backfill ports, butthe present subject matter is not so limited.

A hermetically sealed device housing 110 is used to house components,such as the battery 106, the electronics 104, and the capacitor 108.Hermeticity is provided by welding components into the hermeticallysealed device housing 110 in certain examples. Other examples bondportions of the housing 110 together with an adhesive such as a resinbased adhesive such as epoxy. Accordingly, some examples of the housing110 include an epoxy sealed seam or port. Several materials can be usedto form housing 110, including, but not limited to, titanium, stainlesssteel, nickel, a polymeric material, or combinations of these materials.In various examples, the housing 110 and the case 112 are biocompatible.

The battery 106 is improved by the present electrode technology in partbecause it can be made smaller. In certain examples, it ismanufacturable with less expense. The improvement provided by theseelectrodes is pertinent to any application where high-energy,high-voltage, or space-efficient batteries are desirable.

FIG. 2 is an implanted medical system including a battery that includesa 3D framework, according to some examples. The system includes acardiac rhythm management device 202 coupled to a first lead 204 toextend through the heart 206 to the right ventricle 208 to stimulate atleast the right ventricle 208. The system also includes a second lead210 to extend through the heart 206 to the left ventricle 212. Invarious examples, one or both of the first lead 204 and the second lead210 include electrodes to sense intrinsic heart signals and to stimulatethe heart. The first lead 204 is in direct contact (e.g., touching) withthe right atrium 214 and the right ventricle 208 to sense and/orstimulate both of those tissue regions. The second lead 210 is in directcontact with the right atrium 216 and the right ventricle 212 to senseand/or stimulate both those tissue regions. The cardiac rhythmmanagement device 202 uses the lead electrodes to deliver energy to theheart, between electrodes on the leads or between one or more leadelectrodes and the cardiac rhythm management device 202. In someinstances, the cardiac rhythm management device 202 is programmable andwirelessly communicates 218 programming information with a programmer220. In certain examples, the programmer 220 wirelessly 218 charges anenergy storage device of the cardiac rhythm management device 202. Otherstimulation topologies, such as those that stimulate other portions ofthe body, additionally benefit from the devices and methods disclosedherein.

FIG. 3A is a perspective view of a 3D framework 300, according tovarious examples. FIG. 3B is a close-up view of a 3D framework such asthe close-up view 3B depicted in FIG. 3A. The 3D framework pictured isporous and cathodic, but the present subject matter is not so limited.The 3D framework 300 is metallic in certain examples. As used herein,metallic materials are of, or relate to, being a metal, containing ametal or having properties of a metal. Metallic materials are formed ofaluminum, titanium, stainless steel, other metals and combinations ofthose metals. In certain examples, the 3D framework 300 is continuous. Acontinuous metal demonstrates a regular distribution of grainboundaries, as opposed to a discontinuous metal with between grainboundaries, such as welded metals.

In some instances, the 3D framework is formed of foam. Some examplesinclude metallic foams. In various examples, the 3D framework 300 isformed of metallic foam defining porous cells. In FIG. 3B, a cell 310 isdefined by the framework 304. The cell, according to various examples,represents a bubble in the foam. At least some of the cells are open.Pores 306 provide fluid communication with other cells. Ionic conductionoccurs through the pores, for example.

In various examples, the 3D framework 300 is pliable. For example, the3D framework 300 can be compressed elastically, in certain examples.Some examples include a 3D framework compressed inelastically. As usedherein, compressed relates to cells of foam pressed together and reducedin size or volume, such as by pressure. Compressed additionally meansthat the 3D framework 300 is flattened as though subjected tocompression.

In certain examples, the 3D framework 300 is at least partially filledwith an active material. In certain examples, the active material isdisposed in slurry. Slurry, in general, is a thick suspension of solidsin a liquid. In some instances, the active material is impregnated intothe 3D framework 300.

In various examples, the active material includes, but is not limitedto, carbon monofluoride, with a formula CF_(x). In some examples, thecurrent collector is substantially free of graphite. In certainexamples, one or both of the 3D framework 300 and the active materialare substantially free of carbon black. Examples of carbon blackinclude, but are not limited to, acetylene black such as SHAWINIGANBLACK, (“SAB”). SHAWINIGAN BLACK is a registered trademark of ChevronPhillips, headquartered in Houston, Tex.

In some instances, one or both of the 3D framework 300 and the slurryare compressed. In certain examples, a compressed 3D framework 300including a compressed active material has a porosity of from around45-55% porous. In various examples, the 3D framework provides anelectrical network for electronic conduction, such as between an activematerial and a battery terminal. A benefit some instances provide isthat the 3D framework reduces cathode swelling upon discharge andcompressed powder spring-back.

In certain examples, a CF_(x) cathode including a pressed pellet designwithout a 3D framework has a cathode porosity of around 58%. In certainexamples, a 1.2 amp-hour battery has a predetermined volume and acathode porosity of around 63%.

Certain examples include foam impregnated with CF_(x) to have cathodeporosity is around 52%. One of these examples has a formulation ofaround 11% aluminum, 2% polyvinylidene fluoride (“PVDF”), and 87% CFx.In at least some of the examples, a 1.2 amp-hour battery having acathode specific capacity of 700 milliamp-hours per gram occupies around3.46 cubic centimeters.

In some examples, a CF_(x) cathode including a coated foil designwithout a 3D framework has a cathode porosity of around 73%. In some ofthese examples, the cathode delaminates undesirably. Some instances havea formulation of 3% graphite, 2% SAB, 7% PVDF and 88% CF_(x), coated onaluminum foil. In certain examples, a 2.0 amp-hour battery has a volumeof 9.3 cubic centimeters. Some of these examples comprise seven cathodelayers in a stack of electrodes.

Some examples include an electrode with a porosity of from around 30-55%porous. Certain examples include foam impregnated with CF_(x) that has acathode porosity around 52%. Some of these examples have a formulationof around 11% aluminum, 2% polyvinylidene fluoride (“PVDF”), and 87%CF_(x). In at least certain examples that include CF_(x) in a 3Dframework, a 2.0 amp-hour battery having a cathode specific capacity of625 milliamp-hours per gram occupies around 6.7 cubic centimeters. Someof these examples comprise cathode layers in a stack of electrodes.

In one example, a 1.2 amp hour MnO₂ battery having a gravimetriccapacity of 308 milliamp hours per gram has a volumetric capacitor of1540 milliamp hours per cc has a volume of at least 3.91 cubiccentimeters. A 2.0 amp hour battery having a similar specific andvolumetric capacity has a volume of around 8.64 cubic centimeters.

Contrast CF_(x) battery examples including a 3D framework. Someinstances have a cathode specific capacity of 860 milliamp hours pergram has a volumetric capacity of 2322 milliamp hours per cc has avolume of less than 3.46 cubic centimeters. A 2.0 amp hour batteryhaving a similar gravimetric and volumetric capacity has a volume ofless than 6.0 cubic centimeters.

FIG. 4A is a plan view of a 3D framework 400, according to variousexamples. FIG. 4B is a cross section taken along line 4B-4B in FIG. 4A.The electrode 400 is impregnated with slurry and compressed in theseexamples. The electrode defines a plurality of pores 404. In certainexamples, the electrode has an electrode shape 406 that is selected toat least partially mate a battery case shape. In some instances, theelectrode 400 is cut, such as by routing or another cutting operation.In some examples, the electrode has a flat surface 408. In certainexamples, additional electrodes are stacked onto the flat surface 408.An electrode stack includes a number of electrodes, each including atleast one major face that faces a major face of another electrode. Insome instances, a plurality of electrodes are disposed in a stack andinterconnected with one another. Interconnection is via a conductiveinterconnect, in some examples. Examples of an interconnect include, butare not limited to, a weld busbar, rivet, metal spray and the like.

In various examples, the width W₄ and the thickness T₄ are selected suchthat the electrode 400 conforms to or mates with a selected battery caseshape. Examples include a 3D framework 402 that is connected to aconductor. In certain examples, the electrode 400 is coupled to aconductor. A conductor is welded to the 3D framework 402 such that it iselectrically and physically coupled to the 3D framework 402, in certainexamples. In various examples, a device housing has a form factor, andthe battery case is shaped to at least partially conform to the formfactor.

FIG. 5A is a perspective view of an electrode 500, according to someexamples. FIG. 5B is a cross section taken along line 5B-5B. Activematerial 502 is disposed onto an internal portion 504 of a currentcollector 510. A connection member 506 extends outside the activematerial 502. In some instances, the internal portion 504 of the currentcollector spans the entire width of the active material 502, butexamples in which it spans less than the entire width W₅ areadditionally possible. In certain examples, further currently collectormaterial, such as metallic foam, is coupled to the internal portion 504such as by welding.

As shown, the internal portion 504 comprises fins 512 extending awayfrom an internal support 514. In some instances, the fins 512 are plateshaped and linear. In certain examples, they're curvilinear. In certainexamples, the internal support 514 is plate shaped. In some instances,it is a plate defining many openings, such as circular openings. In someexamples, it is a grid. In additional examples, it is a web. In variousexamples, the fins 512 are orthogonal to the internal support 514.

FIG. 6A is a perspective view of an electrode 600, according to certainexamples. FIG. 6B is a cross section taken along line 6B-6B. Activematerial 602 is disposed onto an internal portion 604 of a currentcollector 610. A connection member 606 extends outside the activematerial 602. In some examples, the internal portion 604 of the currentcollector spans the entire width of the active material 602, butexamples in which it spans less than the entire width W₆ areadditionally possible. In some instances, further currently collectormaterial, such as metallic foam, is coupled to the internal portion 604such as by welding.

As shown, the internal portion 604 comprises canted fins 612 extendingaway from an internal support 614. In certain examples, the canted fins612 are plate shaped and linear. In certain examples, they'recurvilinear. In some instances, the internal support 614 is plateshaped. In certain examples, it is a plate defining many openings, suchas circular openings. In some instances, it is a grid.

FIG. 7A is a perspective view of an electrode 700, according to someexamples. FIG. 7B is a cross section taken along line 7B-7B. Activematerial 702 is disposed onto an internal portion 704 of a currentcollector 710. A connection member 706 extends outside the activematerial 702. In certain examples, the internal portion 704 of thecurrent collector spans the entire width of the active material 702, butexamples in which it spans less than the entire width W₇ areadditionally possible. In certain examples, further currently collectormaterial, such as metallic foam, is coupled to the internal portion 704such as by welding.

As shown, the internal portion 704 comprises layers 712 extending awayfrom an interconnect 708. In some instances, the layers 712 are plateshaped and linear. In certain examples the layers 712 are parallel toone another. In some examples, a spacer spaces the layers apart.Accordingly, in some instances, the layers 712 are in a spaced-apartstack. In certain examples, they're curvilinear. In some instances, oneor more of the layers 712 include a plate defining many openings, suchas circular openings. In certain examples, the layers 712 include agrid.

FIG. 8A is a plan view of a battery, according to various examples. FIG.8B is a cross section taken along the line 8B-8B in FIG. 8A. Variousexamples include a battery stack 818 disposed in a battery case 801. Thebattery case 801, in various examples, includes a dish shaped portion830 and a lid 832, with the lid sealed to the dish shaped portion 830,but the present subject matter is not so limited.

In various examples, the battery stack 818 includes a plurality ofelectrodes and separator. For example, a first separator 820 is disposedbetween the case 801 and a first electrode including a 3D framework 802to physically separate the electrode including a 3D framework 802 fromthe case 801. In certain examples, the electrode including a 3Dframework 802 is coupled to a conductor 810. Some instances include asecond electrode including a 3D framework 804 coupled to a conductor812. Some examples include a third electrode including a 3D framework806 coupled to a conductor 815. In certain examples, the first, secondand third electrodes abut and are in electrical communication with oneanother. In additional examples, the first, second and third electrodesabut the battery case 801. In some examples, the first, second and thirdelectrodes are cathodic. In various examples, the stack 818 is a stackof compressed electrodes, each adapted to stack into the stack. Anelectrode adapted for stacking, in some instances, is prepared inpelletized before stacking. In certain examples, electrodes in a stackare compressed after stacking.

In certain examples, the first, second and third electrodes areelectrically coupled via an interconnection between the first conductor810, the second conductor 812 and the third conductor 815.Interconnection between the first conductor 810, the second conductor812 and the third conductor 815 is via a conductive interconnect. Eachof the conductors is electrically coupled to a respective 3D frameworkvia welding and the like. In some instances, a conductor is formed of ametallic spray. Certain examples include a metallic ribbon coupled tothe 3D framework.

In various examples, a feedthrough 837 including an electrical insulator835 and a terminal 836 is disposed through the dish shaped portion 830and placed into connection with the first conductor 810, the secondconductor 812 and the third conductor 815 such as by welding.

Various examples additionally include a further electrode 816. Invarious examples, one or more separators 808 separate the furtherelectrode 816 from additional electrodes, such as the electrodeincluding conductor 815. In additional examples, a separator 822separates the further electrode 816 from the case 801 such as byseparating the further electrode 816 from the lid 832.

In various examples, the first, second and third electrodes are stackedinto the dish shaped portion 830. Separator is stacked onto the thirdelectrode, and a further electrode 816 is stacked into the dish shapedportion 830. In various examples, a lid 832 is fixed to the dish shapedportion, with a feedthrough 825 including an electrical insulator 824and a terminal 814 is disposed through the lid 832 and placed intoconnection with the further electrode 816 such as by welding. In someexamples, the further electrode 816 is welded to the feedthrough priorto fastening the lid 832 to the dish shaped portion 830.

FIG. 9 is a method of making a battery including a 3D framework,according to certain examples. At 902, the method includes mixingslurry. In some examples, mixing a slurry includes combining anelectrochemically active component with carbon. In certain examples, italso includes mixing in a binder. In some examples, it also includesmixing in a solvent. The slurry is randomized or mixed with a planetarytype mixer, in some examples. At 904, the method includes forming anelectrode including injecting the slurry into a current collectorframework. At 906, the method includes drying the slurry. At 908, themethod includes compressing the electrode. Optionally, this includescompressing the current collector framework after slurry is injected. At910, the method includes cutting the electrode. Optionally, theelectrode is cut after slurry is injected into the current collectorframework. At 912, the method optionally includes stacking the electrodeonto a further electrode.

FIG. 10 is a method of making a battery including a 3D framework,according to some instances. At 1002, the method includes disposingactive material into a current collector including a 3D framework. At1004, the method includes curing the active material to the currentcollector. At 1006, the method includes compressing the 3D framework andactive material into a shaped electrode. At 1008, the method includesstacking the shaped electrode into a battery stack with otherelectrodes. At 1010, the method includes disposing the battery stack ina battery case. At 1012, the method includes connecting the electrodesof the battery stack to terminals for coupling to electronics. At 1014,the method includes filling the battery case with electrolyte. At 1016,the method includes sealing the battery case.

FIG. 11 is a method of making a battery including a 3D framework,according to certain examples. At 1102, the method includes forming aslurry, including mixing solvent and active material including CFx.Forming optionally includes mixing binder or conductive additive. At1104, the method includes Injecting slurry into a current collectorframework substantially filling voids. At 1106, the method includesDisposing Injected current collector in an oven to dry off solvents toprovide a cathode including active material within the current collectorframework. At 1108, the method includes placing dried cathode in a pressand compressing to porosities of 30-40%. Optionally, the currentcollector binds active material. At 1110, the method includes routingthe cathode assembly to a predetermined shape. At 1112, the methodincludes Stacking the cathode with an anode selected to provide apredetermined cell foam energy density.

Aspects of the methods of FIGS. 6, 7 and 11 can be used in combination.Some methods additionally include forming the 3D framework out ofmetallic foam. Some methods include forming the active material bymixing carbon monoflouride into slurry with binder and conductiveadditive. In some methods, disposing active material includes injectingthe active material into the 3D framework. In some methods, curing theactive material includes baking the active material in an oven. In somemethods, compressing the 3D framework includes compressing to a porosityof from around 30% to 40%. Some methods include cutting an excisedelectrode from the shaped electrode. Some methods include stacking theother electrodes into the stack such that the stack has a predeterminedenergy density. In some methods, a stack is formed by a processcomprising stacking an uncompressed electrode and a further uncompressedelectrode into an uncompressed stack, and stacking the uncompressedstack.

This application is intended to cover adaptations or variations of thepresent subject matter. It is to be understood that the abovedescription is intended to be illustrative, and not restrictive. Thescope of the present subject matter should be determined with referenceto the appended claims, along with the full scope of legal equivalentsto which such claims are entitled.

What is claimed is:
 1. A method of making a battery, comprising:disposing active material, including carbon mono fluoride with a formulaCFx into a current collector including an electrically-conductive, metalframework defining open areas disposed along three axes; curing theactive material to the current collector; compressing theelectrically-conducive, metal framework into a pelletized electrode;stacking the pelletized electrode into a battery stack with a secondpelletized electrode; disposing the battery stack in a battery case;connecting the battery stack to terminals for coupling to electronics;filling the battery case with electrolyte; and sealing the battery case.2. The method of claim 1, further comprising forming theelectrically-conductive, metal framework out of a metallic foam.
 3. Themethod of claim 1, further comprising forming the active material bymixing the carbon monoflouride into a slurry with binder and conductiveadditive.
 4. The method of claim 1, wherein disposing active materialincludes injecting the active material into the electrically-conductiveframework.
 5. The method of claim 1, wherein curing the active materialincludes baking the active material in an oven.
 6. The method of claim1, wherein compressing the electrically-conductive, metal frameworkincludes compressing to a porosity of from around 30% to 40%.
 7. Themethod of claim 1, further comprising cutting an excised electrode fromthe pelletized electrode.
 8. The method of claim 1, wherein stackingincludes stacking the pelletized electrode into a battery stack with thesecond pelletized electrode such that the stack has a predeterminedenergy density.
 9. A method of making a battery, comprising: forming anelectrically-conductive metal framework out of metallic foam, theelectrically-conductive metal framework defining open areas disposedalong three axes; forming active material, including mixing carbonmonoflouride with a formula CFx into a slurry with binder and conductiveadditive; injecting the active material into theelectrically-conductive, metal framework; curing the active material tothe current collector; compressing the electrically-conducive, metalframework into a pelletized electrode; stacking the pelletized electrodeinto a battery stack with a second pelletized electrode; disposing thebattery stack in a battery case; connecting the battery stack toterminals for coupling to electronics; filling the battery case withelectrolyte; and sealing the battery case.
 10. The method of claim 9,wherein curing the active material includes baking the active materialin an oven.
 11. The method of claim 9, wherein compressing theelectrically-conductive, metal framework includes compressing to aporosity of from around 30% to 40%.
 12. The method of claim 10, whereinstacking includes stacking the pelletized electrode into a battery stackwith the second pelletized electrode such that the stack has apredetermined energy density.